U.S. patent number 4,115,492 [Application Number 05/763,480] was granted by the patent office on 1978-09-19 for process for preparing microporous polyethylene hollow fibers.
This patent grant is currently assigned to The Dow Chemical Company. Invention is credited to Robert D. Mahoney, Stephen E. Schneider.
United States Patent |
4,115,492 |
Mahoney , et al. |
September 19, 1978 |
Process for preparing microporous polyethylene hollow fibers
Abstract
Normally hydrophobic, polyethylene hollow fibers having
contiguous microporosity are prepared by extruding a heated
solution of a polyethylene and an ester from a hollow fiber
spinnerette, simultaneously cooling and drawing the forming fibers
to a ratio of up to 40 to 1, drawing the gelled fibers to an
overall ratio of from about 1.5/1 to 800/1 and then removing the
ester. The maximum pore radius ranges up to about 50A, and the
fibers have gas permeabilities approaching 10.sup.-2 cc (STP) per
cm.sup.2 per second per cm. Hg. transmembrane pressure
differential. A significant increase in permeability over
polyethylene hollow fibers made according to the teachings of the
prior art is achieved.
Inventors: |
Mahoney; Robert D. (Dublin,
CA), Schneider; Stephen E. (Concord, CA) |
Assignee: |
The Dow Chemical Company
(Midland, MI)
|
Family
ID: |
24481902 |
Appl.
No.: |
05/763,480 |
Filed: |
January 28, 1977 |
Related U.S. Patent Documents
|
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
619431 |
Oct 3, 1975 |
4020230 |
|
|
|
Current U.S.
Class: |
264/49;
264/288.8; 264/211; 264/344 |
Current CPC
Class: |
B01D
67/003 (20130101); B01D 69/08 (20130101); D01D
5/24 (20130101); B01D 67/0027 (20130101); B01D
71/26 (20130101); Y10T 428/2975 (20150115) |
Current International
Class: |
B01D
69/00 (20060101); B01D 67/00 (20060101); B01D
71/26 (20060101); B01D 71/00 (20060101); B01D
69/08 (20060101); D01D 5/00 (20060101); D01D
5/24 (20060101); B29H 007/20 () |
Field of
Search: |
;428/398 ;264/205,41R
;260/31.4R ;210/5M |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Woo; Jay H.
Attorney, Agent or Firm: Stringham; Robert R.
Parent Case Text
This is a division of application Ser. No. 619,431 filed Oct. 3,
1975, now U.S. Pat. No. 4,020,230.
Claims
We claim:
1. A process for preparing a hollow fiber which consists
essentially of polyethylene and is a microporous hollow fiber in
which the porosity is contiguous and the O.sub.2 gas permeability
is at least 2.times.10.sup.-5 cc (STP) per cm.sup.2 per second per
cm Hg transmembrane pressure differential, said process
comprising:
(a) providing a polyethylene/ester mixture of which about 20 to
about 80 weight percent consists essentially of polyethylene and
the balance consists essentially of an ester or a mixture of
esters, of the formula R.sup.1 (COOR.sup.2).sub.n, wherein n is 1
or 2, R.sup.1 is a mono- or divalent hydrocarbon radical,
optionally interrupted by one or two --O-- or --S-- links, and
containing from 1 to 32 carbons, each R.sup.2 independently is an
aliphatic hydrocarbon radical of 2-26 carbon atoms or consists of
two aliphatic hydrocarbon moieties joined by an --O-- or --S-- link
and containing a total of from 3 to 20 carbons;
(b) heating said polyethylene/ester mixture to a temperature at
which it is a homogeneous liquid but below the boiling or
decomposition temperature thereof, and extruding it from a
spinnerette in the form of a hollow fiber;
(c) cooling the issuing extrudate to solidify it while maintaining
sufficient tension on the forming fiber to achieve a draw ratio of
from about 1.0/1 to about 40/1;
(d) at a temperature above the melting point of the ester, but at
least 10.degree. below the cloud point of said homogeneous liquid,
post-spin drawing the solidified fiber under sufficient tension to
achieve an overall draw ratio of from about 1.5/1 to about 800/1;
and
(e) contacting the post-spin drawn fiber with a liquid
ester-removal medium, at a temperature intermediate of the freezing
point of the medium and the flow point of the polyethylene, until
at least a major proportion of the ester is removed from the
fiber.
2. The process of claim 1 in which said ester has the formula
R.sup.1 --COOR.sup.2, in which R.sup.1 is a monovalent radical
defined as in claim 1 and R.sup.2 consists of two aliphatic
hydrocarbon moieties joined by an --O-- link and containing a total
of from 3 to 20 carbons.
3. The process of claim 1 in which R.sup.1 is an aliphatic radical
containing from 10 to 24 carbons.
4. The process of claim 1 in which said ester has the formula
R.sup.1 --COOR.sup.2, in which R.sup.1 is a monovalent radical
defined as in claim 1 and R.sup.2 is an aliphatic hydrocarbon
radical of 2-20 carbon atoms.
5. The process of claim 2 in which said ester is butyl stearate or
2-butoxyethyl oleate.
6. The process of claim 2 in which said ester is 2-butoxyethyl
oleate.
7. The process of claim 1 in which said post-spin drawn fiber is
contacted with methylene chloride or ethanol until the residual
content of said solvent therein is less than 5 weight percent.
8. The process of claim 1 in which said overall draw ratio is
within the range of from about 20/1 to about 500/1.
Description
BACKGROUND OF THE INVENTION
The advantages of permeable hollow fibers as separatory membranes
are now well known. For example, the large membrane areas per unit
volume of device attained with this membrane configuration are of
particular importance in minimizing priming blood requirements for
devices such as so-called artificial kidney or artificial lung
units. Additionally, a simplification over flat membrane devices is
realized in that hollow fibers, by reason of their cross-sectional
shape, are essentially self-supporting and do not collapse under
the transmembrane pressures required for processes such as reverse
osmosis of sea water.
Polyethylene is a particularly attractive material for hollow fiber
manufacture because it is inexpensive, relatively inert, non-toxic,
readily processed and strong. Polyethylene hollow fibers would be
expected to lack the hydrophilicity which is characteristic of the
types of membranes which have been most widely used; i.e., in such
processes as recovery of water from brines by reverse osmosis.
However, hydrophilicity is not essential for permeability
separations such as removal of dissolved gases from aqueous or
non-aqueous solutions or ultrafiltration of organic solutions
containing relatively large solute molecules.
The only process known to Applicants for making polyolefin hollow
fibers is that disclosed in U.S. Pat. No. 3,423,491, which teaches
the preparation of permselective hollow fibers by melt spinning a
mixture of a thermoplastic polymer and a plasticizer, cooling and
leaching out the plasticizer. The following plasticizers, disclosed
as leachable with alcohols or aromatics, are listed as suitable for
the fabrication of semi-permeable hollow fibers from polyolefins:
dioctyl phthalate, polyethylene wax, tetrahydronapthalene and
chlorinated biphenyls.
It is apparent from the data given in the U.S. Pat. No. 3,423,491
(for cellulose triacetate fibers) that the membrane structures
obtained by the disclosed process are much "tighter" than is
required for the types of separations for which polyolefin hollow
fibers appear to be most suitable. A microporous structure, in
which selectivity results primarily from pore size rather than from
the chemical nature of the membrane material, would appear to be
preferable.
U.S. Pat. No. 3,745,202 is directed to the preparation of porous
hollow fibers having a semipermeable outer layer or "skin". A
mixture of a cellulose ester or ether with a plasticizer is melt
spun and the resulting molten hollow fiber is drawn, gelled by
cooling and leached to remove the plasticizer. At this stage, the
fiber structure is said to have a graded porosity but to lack the
outer skin required for selectively. After a following treatment
with hot water, the fibers are said to be more crystaline and more
permeable but require further treatment for attainment of
selectivity.
U.S. Pat. No. 3,093,612 (corrected to 3,092,612) is directed to
polyolefin/alkoxyalkyl ester compositions which are suitable for
the preparation of solid polyolefin filaments comprising "small
pores" which are not contiguous. A polyolefin/ester mixture is
heated to form a solution, forced through a spinnerette, solidified
by cooling and immersed in a wash bath, such as isopropanol. The
resultant fiber is air dried and then stretched (drawn) to achieve
a maximum degree of orientation. Most of the solvent (ester) is
said to be removed during coagulation of the fiber and the rest
(except for a residual solvent content) by washing.
OBJECTS OF THE INVENTION
A primary object of the present invention is to provide normally
hydrophobic, microporous hollow fibers which have high gas
permeabilities and can be prepared from a strong, inert,
inexpensive and readily processed polymer, i.e., from
polyethylene.
A further object is to provide a flexible, practical process for
making such fibers.
An additional object is to provide microporous, polyethylene hollow
fibers having particular utility as separatory membranes in
so-called artificial lungs or oxygenators.
Another object is to provide novel hollow fibers having gas
permeabilities up to an order of magnitude greater than hollow
fibers of the same size and composition which are made according to
the teachings of the prior art.
Yet another object is to provide microporous, oleophilic hollow
fibers which, when pore wetted, have utility as separatory
membranes in ultrafilters and dialyzers.
It is also an object to provide a process for making microporous,
polyethylene hollow fibers in which the permeability of the fibers
can be controlled simply by choice of a leaching medium and contact
time.
SUMMARY DESCRIPTION OF THE INVENTION
It has now been discovered that microporous, normally hydrophobic
hollow fibers can be prepared by spinning a homogeneous solution of
polyethylene and an alkoxyalkyl ester in hollow fiber form, gelling
the forming fibers, drawing the fibers in a solidified gel state
and then contacting the drawn fibers with a liquid ester-removal
medium and removing at least a major proportion of the ester. The
pores in the resultant fibers are contiguous between the inner and
outer fiber surfaces, and are of a size suitable for applications
such as blood oxygenation, ultrafiltration, dialysis, etc. The
fibers have O.sub.2 permeabilities of from about 2 .times.
10.sup.-5 to about 1 .times. 10.sup.-2 c.c. per cm.sup.2 per second
per cm Hg. transmembrane pressure.
It has also been discovered that other types of esters which form
homogeneous melts with polyethylenes can be employed in place of
the preceding alkoxyalkyl esters.
More precisely, the fiber and process of the present invention, and
preferred embodiments thereof, may be defined as follows:
(1) A microporous hollow fiber in which the porosity is contiguous,
the O.sub.2 gas permeability is at least 2 .times. 10.sup.-5 c.c.
(STP) per cm.sup.2 per second per cm Hg. transmembrane pressure
differential and said fiber consists essentially of
polyethylene.
(2) A fiber as in embodiment 1 in which said oxygen gas
permeability is at least 1 .times. 10.sup.-3.
(3) A fiber as in embodiment 1 having an oxygen gas permeability,
as therein defined, of at least 2 .times. 10.sup.-3.
(4) A fiber as in embodiment 1, of which 10 weight percent or less
is derived from olefins other than ethylene.
(5) A process for preparing a hollow fiber according to embodiment
1 which comprises:
(a) providing a polyethylene/ester mixture of which about 20 to
about 80 weight percent consists essentially of polyethylene and
the balance consists essentially of an ester, or a mixture of
esters, of the formula R.sup.1 (COOR.sup.2).sub.n, wherein n is 1
or 2 R.sub.1 is a mono- or divalent hydrocarbon radical, optionally
interrupted by one or two --O-- or --S-- links, and containing from
1 to 32 carbons, each R.sub.2 independently is an aliphatic
hydrocarbon radical of 2-26 carbon atoms or consists of two
aliphatic hydrocarbon moieties joined by an --O-- or --S-- link and
containing a total of from 3 to 20 carbons,
(b) heating said polyethylene/ester mixture to a temperature at
which it is a homogeneous liquid but below the boiling or
decomposition temperature thereof, and extruding it from a
spinnerette in the form of a hollow fiber,
(c) cooling the issuing extrudate to solidify it while maintaining
sufficient tension on the forming fiber to achieve a draw ratio of
from about 1.0/1 to about 40/1,
(d) at a temperature above the melting point of the ester, but at
least ten degrees below the cloud point of said homogeneous liquid,
post-spin drawing the solidified fiber under sufficient tension to
achieve an overall draw ratio of from about 1.5/1 to about
800/1,
(e) contacting the post-spin drawn fiber with a liquid
ester-removal medium, at a temperature intermediate of the freezing
point of the medium and the flow point of the polyethylene, until
at least a major proportion of the ester or ester mixture is
removed from the fiber.
(6) The process of embodiment 5 in which said ester has the formula
R.sup.1 --COOR.sup.2, in which R.sub.1 is a monovalent radical
defined as in embodiment 5 and R.sup.2 consists of two aliphatic
hydrocarbon moieties joined by an --O-- link and containing a total
of from 3 to 20 carbons.
(7) The process of embodiment 5 in which R.sup.1 is an aliphatic
radical containing from 10 to 24 carbons.
(8) The process of embodiment 5 in which said ester has the formula
R.sup.1 --COOR.sup.2, in which R.sup.1 is a monovalent radical
defined as in embodiment 5 and R.sup.2 is an aliphatic hydrocarbon
radical of 2-20 carbon atoms.
(9) The process of embodiment 6 in which said ester is butyl
stearate or 2-butoxyethyl oleate.
(10) The process of embodiment 6 in which said ester is
2-butoxyethyl oleate.
(11) The process of embodiment 5 in which said post-spin drawn
fiber is contacted with methylene chloride or ethanol until the
residual content of said ester therein is less than 5 weight
percent.
(12) The process of embodiment 5 in which said overall draw ratio
is within the range of from about 20/1 to about 500/1.
DETAILED DESCRIPTION OF THE INVENTION
Suitable polyethylenes for the practice of the present invention
are those consisting essentially of units formed by polymerization
of ethylene. Polymer units derived from other monomers preferably
are not included but may be present in such minor amounts that the
essential character of the polyethylene is not lost. Said amounts
will generally not exceed about 15 weight percent and desirably are
less than about 10 weight percent. Generally, said fiber contains
at least about 85 weight percent polyethylene. Preferably, said
fibers contain at least about 90 weight percent polyethylene.
Preferably, any non-ethylenic units present are derived from
olefinic monomers. It is also preferred that any non-ethylenic
units be incorporated as one or more copolymeric components with
ethylene. However, discrete homo- or copolymers which are
compatible with the polyethylene may be incorporated by known
techniques, such as melt blending or solution blending. This, of
course, is with the provision that the incorporated material will
be retained in the finished microporous fiber as part of a
substantially homogeneous microstructure, i.e., that it will not be
phase separated or lost during post-spinning processing.
It should be noted that the hollow fibers of the present invention
may include residual ester contents which are not so high as to
result in loss of their essential polyethylene character.
Preferably, the process of the present invention is carried out in
such manner that the resulting fibers contain 5% or less of the
ester by weight.
Suitable polyethylenes include those which are more branched and
less regular, i.e., the so-called "low density" polyethylenes, as
well as the more linear, more highly crystalline polyethylenes of
the Ziegler and Phillips types, commonly referred to as "high
density" polyethylenes.
Such parameters as linearity, crystallinity, average molecular
weight and molecular weight distribution are significant largely to
the extent to which they are determinative of properties such as
tensile strength, flexibility, solubility and melting (or flow)
points. The prior art knowledge of these types of dependencies is
such as to provide considerable guidance in the selection or design
of a polyethylene composition from which to make hollow fibers
having the properties (other than porosity) suitable for a
particular application. Furthermore, the applications for which
fibers of a given polyethylene are most suitable can readily be
checked by a combination of standard fiber evaluation tests
(tensile strength per denier, for example) and the permeability
determination procedures described in the examples herein.
Suitable monomers co-polymerizeable with ethylene are exemplified
by olefins, styrene, vinylpyridines, butadiene, acetylene,
cyclopentadiene, acrylonitrile, vinyl chloride, vinyllidine
chloride, allyl alcohol, diallyl ether, maleic anhydride,
tetrafluoroethylene, divinylbenzene monoxide, N-vinylpyrollidone,
vinylisobutyl ether, vinyl acetate, vinyl dimethyl boron,
cyclohexene, phenylpentenyl thioether, N-methyl-N-butenyl aniline,
styrene sulfonic acid and alpha, alpha'-dichloro-p-xylene.
Exemplary suitable olefins co-polymerizeable with ethylene are
propylene, 1-butene, isobutylene, 1-pentene, 4-methylpentene-1,
2-butene, 2-pentene, 2-methylbutene-1, 2-methylbutene-2,
3-ethylbutene-1, 1-hexene, 2-hexene, 1-heptene, 1-octene,
1-tridecene, 1-hexadecene and 3-ethyloctadecene. Polymers of
olefins containing up to 20 carbons and methods of preparing such
polymers are disclosed in numerous publications, including an
extensive patent literature. Reference may also be had to
compendiums, such as the Encyclopedia of Polymer Science and
Technology; Interscience, 1968, volume 9.
Suitable types of non-olefinic polymers which may be incorporated
in minor amounts are exemplified by homo- and copolymers of the
above listed non-olefin monomers and by nylons, polyesters,
polyurethanes, polyalkylene oxides, polyalkylenimines, polyimides,
urea/formaldehyde resins, phenolics, and so on. Preferably, such
polymers are thermoplastic or but lightly crosslinked. In any
event, they are employed only in such amounts as to be miscible
with melts of the polyethylenes with which they are to be blended,
independently of the presence of any esters. The more polar a
polymer of the preceding type is, the lower its solubility in a
molten polyethylene will tend to be. The latter tendency can be
overcome to a limited extent by co-polymerizing minor amounts of
unsaturated monomers containing polar groups with the ethylene
employed. That is, the resulting co-polymers will be somewhat more
compatible with polar polymers. In general, the more polar polymers
are not incorporated in amounts greater than about 10 weight
percent and preferably constitute from 0 to about 5 weight percent
of the material in the fibers produced by the process of the
present invention.
Suitable esters for the practice of the present invention are any
mono- and diesters, as above defined, capable of forming
homogeneous melts with at least one polyethylene as above
defined.
U.S. Pat. No. 3,092,612 describes a number of alkoxyalkyl esters of
aliphatic monocarboxylic acids which will form homogeneous melts
with polyethylene (and other polyolefins). These esters are
represented in the patent by the formula R--COO--R'--O--R', wherein
R is an aliphatic hydrocarbon chain containing from 1 to 32 carbon
atoms and R' is a saturated aliphatic hydrocarbon chain of from 1
to 8 carbons. However, the defining formula, R.sup.1
--(COO--R.sup.2).sub.n, used herein encompasses not only
alkoxyalkyl but also alkoxyalkenyl, alkenyloxyalkyl and
alkenyloxyalkenyl R.sup.2 groups. Further, analogues of the
preceding groups in which the oxygen is either omitted or replaced
by a sulfur are also included.
Diesters of aliphatic or heteroaliphatic dicarboxylic esters,
R.sup.1 (COOR.sup.2).sub.2, in which R.sup.1 and R.sup.2 are as
above defined, are also suitable. Such esters in which R.sup.1 is a
hydrocarbylene moiety of at least 5 carbons are preferred. It is
also preferred that each of the R.sup.2 groups contains at least 4
carbons, particularly when R.sup.1 contains less than 5
carbons.
Similarly, mono- and di-esters as above defined in which R.sup.1 is
a mono- or divalent hydrocarbyl radical consisting of or containing
carbocyclic rings are suitable. Necessarily, R.sup.1 in such esters
comprising an aromatic ring will contain at least six carbons (at
least one benzene ring). Additionally, however, R.sup.1 in the
latter esters may contain one or more aliphatic moieties, each
optionally interrupted by an --O-- or --S-- link, and having a
total of from 1 to 26 carbons. The ester group, or groups
(--CO--O--R.sup.2) may be attached either to aliphatic or
carbocyclic carbons in R.sup.1.
Specific exemplary R.sup.1 groups are included in the acyl(R--CO--)
portions of the monocarboxylate esters listed in U.S. Pat. No.
3,092,612, including those derived from unsaturated acids, such as
acrylic, crotonic, isocrotonic, oleic, erucic and elaidic acids.
Other specific, exemplary R.sup.1 groups, which may be introduced
in esters of the above formula by esterification of various
alcohols, constitute the R.sup.1 group in the following mono- and
dicarboxylic acids of the formula R.sup.1 (COOH).sub.n, being 1 or
2: propiolic acid, benzoic acid, the isomeric cinnamic acids,
2-decalincarboxylic acid, phenylacetic acid, hexacosanoic acid, the
toluic acids, 4-t-butyl-benzoic acid, the biphenylcarboxylic acids,
the napthoic acids, cyclobutanecarboxylic acid, the
octadecatrienoic acids, abietic acid, 9- or -10- phenyloctadecanoic
acid, 3,7,11-trimethyldodeaca-2,4,11-trienoic acid, chrysanthemic
acid, prostanoic acid, napthalenepropionic acids, pimaric acid and
diphenyl acetic acid; phthallic, isophthallic and terephthallic
acids, the cyclopropane dicarboxylic acids,
2,4-cyclohexadiene-1,2-dicarboxylic acid, malonic acid, decanedioc
acid, epitruxillic acid, isocamphoric acid, fumaric acid,
cinnamylidenemalonic acid, cetylmalonic acid, muconic acid, the
naphthalene dicarboxylic acids, norcamphane dicarboxylic acid,
2-phenylpentanedioic acid, roccelic acid,
1-phenyl-1,4-tetralindicarboxylic acid, acetylene dicarboxylic acid
and 1,2-diphenoxyethane-p,p'-dicarboxylic acid.
Specific exemplary alkanol esters suitable for the practice of the
present invention are corresponding mono- or di-esters of the
foregoing acids with any of the following monohydroxy alkanes:
ethanol, isopropanol, t-butanol, neo-pentanol,
2,3-dimethylbutanol-1, pentamethylethanol, n-heptanol,
2-ethyl-hexanol-1, capryl alcohol, lauryl alcohol, pentadecanol-1
and ceryl alcohol.
Specific exemplary --OR.sup.2 groups in which R.sup.2 is an
alkenoxyalkyl, alkoxyalkenyl or alkenoxyalkenyl radical are
derivable from the following alcohols, which may be prepared as
indicated and reacted with an anhydride, R.sup.1 CO--O--CO--R.sup.1
or acyl chloride, R.sup.1 CO--Cl to produce corresponding exemplary
esters R.sup.1 --CO--O--R.sup.2 :
by the reaction of allyl chloride with the monosodium salt of
propylene glycol;
by adduction of methyl vinyl carbinol with ethylene oxide;
by adduction of 5-hexene-2-ol with butadiene monoxide;
by reaction of methallyl chloride with the monopotassium salt of
2-butene-1,4-diol and
by reaction of lauryl iodide and the monosodium salt of
2-butene-1,4-diol.
A wide variety of unsaturated, acyclic alcohols are known.
Exemplary --OR.sup.2 grous in which R.sup.2 is an alkenyl or
alkadienyl radical of from 3 to 20 carbon atoms are derivable from
the following alcohols by standard esterification procedures: allyl
alcohol, crotyl alcohol, 4-pentene-1-ol, methyl vinyl carbinol,
5-hexen-2-ol, geraniol and oleyl alcohol.
Exemplary --OR.sup.2 groups in which the main chain in the
--R.sup.2 radical is interrupted by an -S- moiety are derivable
from the following alcohols, which may be prepared as
indicated:
by adduction of methyl mercaptan with ethylene oxide;
by reaction of sodium hexyl mercaptide with Br--CH.sub.2
--CH.dbd.CH--CH.sub.2 OH;
by reaction of allyl chloride and the sodium salt of
alpha-hydroxypropyl mercaptan;
by addition of isopropyl mercaptan to 6-hepten-1-ol in the presence
of sulfur and absence of peroxides;
by adduction of isobutenyl mercaptan and butadiene monoxide and
by reaction of sodium isobutenyl mercaptide with Br--CH.sub.2
--CH.dbd.CH--CH.sub.2 OH.
The preferred esters (or ester mixtures) for the practice of the
present invention are those, as above defined, which:
a. form homogeneous melts with a polyethylene at a temperature less
than 250.degree. C., when admixed with the polymer in at least one
weight ratio within the specified 20/80 to 80/20 range; and/or
b. are liquids at ordinary ambient temperatures; and/or
c. are readily soluble in a relatively low boiling or
water-miscible liquid which is a poor or non-solvent for the
polyethylene; and/or
d. are readily made or commercially available.
Alkoxy-alkyl esters, such as, for example, those described in U.S.
Pat. No. 3,092,612 have all of the foregoing advantages a-d, and
accordingly are a preferred group of esters. Among this group,
butoxyethyl laurate and butoxyethyl oleate, particularly the
latter, are highly preferred.
Similarly, di-alkyl esters of aromatic dicarboxylic acids
constitute another preferred group of esters. Particularly
preferred esters of this type are dialkyl phthalales such as, for
example, dicaprylphthalates, di(2-ethylhexyl) phthalate
("dioctylphthalate"), di(2-ethylbutyl) phthalate ("dihexyl
phthalate"), diisobutyl phthalate, diisodecyl phthalate and
di(n-octyl, n-decyl) phthalate, all of which have the foregoing
advantages a-d.
Suitable polyethylene/ester weight ratios are from about 20/80 to
about 80/20. In general, membrane permeability will decrease and
selectivity will increase as the proportion of polymer in the
spinning solution is increased. The former effect is particularly
evident for processes requiring separation of gases from (or
introduction of gases to) liquids. In general, the viscosity of the
spinning solution and the strength of the fibers produced will
increase as the proportion of polymer goes up.
What constitutes an ideal combination of fiber properties of course
depends on the contemplated use. However, from the standpoints of
ease of fiber preparation and of obtaining a good compromise set of
fiber properties, a range of from about 30 to about 70 weight
percent polymer in the polymer/ester mixture is preferred.
Method of mixing the polymer and ester(s). The polymer and ester(s)
may be mixed by conventional methods. Polymer particles or strands
may be "dry" mixed with the liquid or particulated ester(s), heated
to form a solution or fluid slurry and then stirred or co-extruded
through a heated ram or screw extruder. A particularly effective
method for mixing other than in situ is to premix as a melt,
re-solidify, fragment and then re-melt and extrude through a hollow
fiber spinnerette.
Suitable spinning temperatures range from the lowest temperature at
which the polymer/ester mixture is a homogeneous liquid up to the
lowest temperature at which boiling or detrimental decomposition
occurs. In general, temperatures at least 10.degree. above the
cloud point of the solution and at least 10.degree. below the
temperature at which any substantial rate of evaporation or
decomposition results will be preferred. Considerations such as the
dependency of viscosity on temperature and the dependency upon
viscosity in turn of spinning solution behavior during and
subsequent to issuance from the spinnerette are familiar to those
skilled in the art of spinning fibers and will not be dwelt upon
here. The optimum spinning temperature for any particular mixture
can be determined empirically and this is readily done by carrying
out a relatively small number of experimental extrusions with a
laboratory type, single orifice spinnerette.
In some instances, the minimum useable spinning temperature may be
determined by the safe working pressure of the equipment used to
force the polymer solution through the spinnerette at the required
rate. That is, the viscosity of the mixture must be low enough to
provide for an adequate rate of spinning under a pressure head
equal to or less than the maximum safe working pressure of the ram,
pump or screw employed. Adjustments in the proportion or
composition of the polymer in the mixture can also be made in order
to increase or decrease viscosity.
Spin temperatures within the range of about 100.degree. to
250.degree. C. will usually be suitable for the polyethylene/ester
mixtures (solutions) employed in the present process. Temperatures
of from about 180.degree. to about 220.degree. are preferred,
however,
Cooling and Initial Drawing
The initial draw is made, to a ratio of from about 1.0/1 to about
40/1, while the extrudate is being cooled and gelled. The fiber
structure must be "set", i.e., solidified or gelled as an
interdispersion of two discrete phases (polymer and ester(s)),
before the post-spin, or following draw is made. It is therefore
desirable to spool or drum the fiber skein as it is withdrawn from
the spinnerette, or otherwise operate, so that the tension exerted
during the subsequent draw will not be transmitted back to as yet
ungelled fiber portions adjacent the orifice(s). Since some tension
will ordinarily be exerted during spooling, it is usually difficult
to avoid some drawing, on the order of about 1.01 to about 1.1/1
for example, during cooling and take-up of the newly formed fibers.
It is also difficult to make spinnerettes having the small
dimensions required for production of thin-walled fibers at lower
draw ratios and relatively high overall ratios will therefore often
be necessary. The attainment of higher overall ratios is a much
more practical operation if it can be effected in two stages.
Fortunately, the initial draw can be as high as about 40/1 without
markedly reducing the beneficial effects on microporosity attained
during the subsequent draw. It has been found that a substantially
more permeable structure results if the final dimensions of the
fiber are not attained while the fiber is being cooled and
solidified.
Cooling can be done by contacting the newly formed fibers with a
cool fluid, such as a quench gas or liquid. If desired, close
control of the temperature profile in the cooling zone can be
attained by flow of a cooling gas through a conduit surrounding the
fiber skein. Alternatively, the fibers may be spooled in or passed
through a body of a quench liquid; optionally, in counter-current
flow. When a quench bath is employed, it may or may not be preceded
by a flow of gas, for cooling or for any other desired effect.
The length of the cooling zone and the lowest temperature therein
will depend on the solidification temperature for the polymer
solution and on how rapidly it is desired to establish this
temperature throughout the entire thickness of the fiber wall. The
temperature needed to cause rapid solidification will be at least
as low as the cloud point of the polymer solution and the
temperature employed will usually be ten degrees or more below this
point.
A wide variety of fluids are suitable for cooling, since
temperatures outside the range of about 0.degree. to 100.degree.
C., will usually not be employed. Such fluids of course should be
poor solvents or non-solvents for the extruded fiber materials.
Cooling fluid temperatures within the range of about 10.degree. to
50.degree. C. are preferred.
In the event that it is desired to employ as the quench bath a
liquid in which the ester(s) to be subsequently removed is
undesirably soluble, sufficient of the ester(s) to suppress
solubility losses may be dissolved in the quench liquid prior to
use. Since the residence time of the fibers in the quench bath will
usually be quite low, only a few percent of the ester(s) will
ordinarily be enough. However, greater amounts, up to the
saturation level, may be employed.
Residence times in contact with the cooling medium should be
minimized when the medium is a liquid, since ester loss will tend
to occur (particularly at higher temperatures) even when the medium
is not miscible with the ester. Preferably, contact with a liquid
quench medium is terminated as rapidly as is practicable after the
fiber has solidified to the desired extent (usually throughout the
entire wall structure). Contact with gaseous cooling media can be
extended indefinitely and is limited only by considerations of
process efficiency.
Post-spin Draw (PSD) Conditions
The cooled, solid fibers are drawn to provide an overall draw ratio
of from about 1.5/1 to about 800/1.
Overall draw ratios of about 10/1 to about 500/1 are generally
preferred over higher ratios, since the PSD step tends to "close
up" the internal structure of the fiber at such higher ratios.
However some polymer solutions, particularly at low polymer
contents, tend initially to be very open and some "closing down"
may be essential to attaining adequate strength and limiting pore
size. Where higher overall ratios, i.e., from about 500 to 800, are
to be employed, it will usually be desirable to take a relatively
high initial draw (up to 40/1), while the polymer and ester mixture
is phasing and gelling. The porosity of the final fiber is not
highly dependent upon the initial draw, which is important
primarily to achieving adequate size reduction without the degree
of porosity reduction which will result if essentially all of the
draw is taken in the PSD step, i,e., after the polymer and ester(s)
are present as discrete phase regions. In general, the overall
ratio for both draws will not exceed that required to provide a
final wall thickness as low as about 10 microns. The fibers are
maintained at or heated to a temperature above the melting point of
the ester or ester mixture but at least ten degrees below the cloud
point of the polymer/ester solution from which the fibers were
spun.
Temperatures of from about 50.degree. to about 110.degree. will
generally be preferred for post-spin drawing, particularly when the
spin mix contains substantially less than about 40 weight percent
of the ester(s). On the other hand, ambient temperatures (about
25.degree.-30.degree. C.) will often be satisfactory when normally
liquid esters or ester mixtures are employed. particularly at ester
levels greater than about 60 weight percent. The PSD fibers are
spooled or drummed under sufficient tension (taken up at a
sufficient rate) to attain the desired overall draw ratio. Any
requisite heat input may be provided by irradiation or by contact
with a heating medium, such as a hot metal roll or a hot gaseous or
liquid fluid.
If a liquid heating medium is employed, it can also function, in an
alternative mode of operation, as the ester removal medium. In this
case, contact with the liquid is prolonged after drawing, usually
in the substantial absence of tension. This can be done, for
example, by passing the fibers through the hot liquid under draw
tension and then taking them up on a spool, drum or frame immersed
in the liquid. Immersion is continued until any desired proportion
of the ester(s) present in the fibers is removed, as by dissolution
and/or by being squeezed out. The removed ester(s), as such or in
solution, are separated by flushing or by gravity separation.
In the PSD operation, it is essential that the fibers be brought to
temperature and drawn before the proportion of ester they contain
drops below the requisite level. An excess of the ester sufficient
to compensate for losses during the initial stage of the PSD
operation, i.e., before drawing, can be included in the original
spin mixture. In this event, a somewhat lower spin temperature may
be required in deference to viscosity requirements for spinning. In
general, it is preferred that no substantial ester loss or removal
occurs prior to the leaching (ester removal) step.
Heating may be carried out in the preceding manner or, preferably,
in other ways. For example, the cooled, solid fibers may be heated
by irradiation or by contact with a hot gas or liquid to the
selected draw temperature while being subjected to the requisite
draw tension, taken up on a drum which is not immersed in the
heating medium and then placed in or passed through a separate
ester removal bath. Optionally, the solid fibers may be preheated,
as by brief immersion in a heating bath, before being subjected to
the drawing tension.
The heating medium should be a poor solvent and preferably is a
non-solvent for the polymer. A particularly preferred medium of the
latter type for draw temperatures up to 100.degree. C. is
water.
Any non-hazardous fluid which is not detrimentally reactive or
instable and is not a good solvent for the polymer can be used as
the heating medium, as the drawing medium, or both. Such liquids as
are miscible with the ester to be removed are preferred for ester
removal but are less desirable as heating or drawing media. The
suitability of a given liquid as a medium can readily be determined
by test. Also, the literature includes a considerable amount of
information on the solubilities of ethylenic polymers in the common
solvents.
The fibers do not necessarily have to be in contact with any medium
during heating and/or drawing. If desired, the fiber two may be
heated by irradiation and drawn while passing through or being
taken up in an evacuated zone.
Ester Removal
The ester(s) present in the drawn fibers are removed by dissolution
in the ester removal medium or by separation as a solid or liquid
phase which is not miscible with the medium. The medium preferably
is capable of dissolving the ester but should be a non-solvent for
the polymer component of the fibers, since ester removal will
generally require substantial contact duration.
Examplary suitable ester removal media are water, alcohols,
ketones, dimethylacetamide, carbon tetrachloride, methylene
chloride and acetonitrile. Methylene chloride and ethanol are
preferred for this purpose. In general, any non-hazardous liquid
which is a non-solvent for the polyethylene and is not instable or
detrimentally reactive may be employed to effect ester removal. The
suitablity of any such liquid for removal of a particular ester is
of course readily determinable by test.
Suitable temperatures for the ester removal operation range from
just above the freezing point of the medium to within about 10
degrees of the flow point of the polyethylene. Temperatures of from
about 20.degree. to about 50.degree. C. are preferred. Temperatures
above 50.degree. C. will generally not be employed if the fibers
are to be subjected to any substantial amount of tension while the
ester is being removed. As a practical matter, temperatures above
the normal boiling point of the medium employed (which require
superatmospheric pressures) will usually not be employed.
Contact between the fibers and the ester removal medium should be
continued until at least a major portion (more than 50%) of the
ester or ester mixture has been removed. Since attainment of higher
permeabilities in the product fibers is dependent on reduction of
the ester content to a low level, it will generally be desirable to
remove as much ester as is possible in an economic period of time.
However, the rate of removal generally decreases as the
concentration of the ester in the fiber decreases and it will thus
often be impractical to effect complete removal.
In general, the rate of ester removal will be higher at more
elevated temperatures and this fact can be taken advantage of when
using higher boiling removal media, such as alcohols.
Optionally, the leached fibers may be left in contact with the
ester removal medium until the micropores are wet with or even
filled with the medium. When this is done with a water miscible
medium, such as ethanol, for example, the medium may then be
displaced with water. This is a convenient method by which the
normally hydrophobic membrane (fibers) may be pore wet and rendered
suitable for carrying out permeability separatory processes with
aqueous solutions or suspensions.
The ester will usually be removed immediately after post-spin
drawing. However, ester removal may be delayed indefinitely. If the
ester content of the unleached fibers does not interfere with
"potting", ester removal may even be delayed until an end device
incorporating the fibers is put into use. Often, however, it will
be preferable to complete device manufacture, i.e., to remove the
ester, before the device is shipped or put into use.
EXAMPLES
The following examples illustrate specific embodiments in the
practice of the present invention.
Typical Procedure
Stage 1
A solution of the polyethylene and the ester is formed in a stirred
and heated vessel, solidified by cooling and cut into pieces. The
particulated mixture is placed in a heated tube, melted and
ram-extruded through a hollow fiber spinnerette, air being pumped
through the center of the spinnerette to keep the forming fiber
continuously hollow. The nascent fiber is passed through an 8-inch
air cooling zone and then, at room temperature, through a quench
bath consisting of two vessels of isopropanol in series, the path
length in each vessel being 40 cm. Upon exiting from the quench
bath, the fiber is taken up at a preselected rate (depending on the
purge rate at the spinnerette and on the initial draw ratio
desired) on a rotating spool.
Stage 2
The hollow fiber is unspooled, and drawn at a preselected
temperature to a preselected overall draw ratio. The drawing is
done manually, as by immersing the fiber portion to be drawn in hot
water, waiting about 10 seconds, drawing over another 10 second
interval to the desired length, waiting about 10 seconds and then
removing the drawn fiber from the water. The same sequence of steps
can be carried out in a continuous, mechanical mode of operation by
methods readily apparent to those skilled in the art of fiber
manufacture.
Stage 3
The hollow fiber is leached in a preselected solvent for a period
of from 1/4 hour to 24 hours.
Stage Ommission or Sequence Alteration
In two of the following experiments, a fiber (or a portion of a
fiber) is leached and then drawn, the sequence of stages 2 and 3
being reversed for purposes of comparison. Leaching is done in most
tests after a fiber portion has been potted in a permeability
testing assembly.
Permeability Measurements
The permeability of a fiber portion is determined after any stage
by cutting off a number of 10 cm. lengths, assembling them with
other components as a so-called beaker ultrafilter and measuring
the rate of permeation of a gaseous or liquid test fluid. The
lengths are arranged in parallel, the resulting bundle is bent in
an inverted U-shape and the ends of the bundle potted in short
sleeves extending side by side from the bottom of a plastic beaker
and fitted with tubing connectors to permit passage of a test fluid
or permeate through the fiber lumen. The bottom of the beaker is
also provided with dialysate inlet and/or outlet connections. The
beaker is inverted and joined by mating threads at its open end to
a shallow cup. The effective membrane area of the fiber bundle is
calculated from the fiber average diameter, the unpotted length of
the fibers and their number (about 10-50, depending on the amount
of fiber available). Gas permeation rates are determined by
pressurizing the exteriors of the fiber lengths with the test gas
and measuring the volume of a liquid displaced by the permeated gas
issuing from the fiber lumen in a given time period. For liquids,
the permeation rate is determined by measuring the volume of liquid
permeate directly. Solute contents in both the feed and permeate
are determined by conventional analytical methods.
In the tabulations of data given in the examples below, the symbols
used have the following meanings: UFR -- ultrafiltration rate -- in
ml of ultrafiltrate per minute per square meter of membrane
surface, adjusted for a standard transmembrane pressure
differential of 300 mm Hg; GPR -- gas permeation rate -- in cc. per
cm.sup.2 of membrane area per second per cm Hg of transmembrane
pressure differential; % Rej. = weight percent of the indicated
solute not passed by the membrane.
EXAMPLE 1
Seven series of microporous hollow fibers were prepared from
polyethylene (Dow high density P.E. resin 70065, melt index 0.70,
density 0.965) having a tensile yield of 4550 lb.f/in.sup.2, a
shore D hardness of 65, an IZOD impact of 2.0, and a Vicat
softening pt. of 127.degree. C.) and 2-butoxyethyl oleate, butyl
stearate or dioctyl phthalate to demonstrate the importance of
post-spin drawing prior to leaching.
These preparations and the properties of the resultant fibers are
summarized in Table 1 below. In the column headed "Stage Sequence",
stage numbers and commas are used to show which of the stages (in
the basic procedure described above) the fibers were subjected to
and in what order. Thus, an entry 1, 2, 3, means stages 1-3 were
employed in their ordinary sequence. The entry 1, 3 means step 2
was omitted and1, 3, 2 means that the sequence of stages 2 and 3
was inverted.
All fibers leached in this example were leached 1/2 hour in
ethanol.
TABLE I DEPENDENCY OF PERMEABILITY ON HOT-DRAWING AND THEN LEACHING
SPINNING & DRAWING CONDITIONS COMPOSITION Initial Overall FIBER
DIMENSIONS(.mu.) P ERMEABILITIES.sup.5 Wt.% Stage Spin Draw PSD
Draw Initial.sup.4 Final.sup.5 % Fiber P.E..sup.1 Ester Sequence
Temp..sup.2 Ratio Temp. Ratio I.D. O.D. Wall I.D. O.D. Wall Gas GPR
Liquid UFR Rej. PE-1 26.2 B.E.O..sup.3 1,3 280 2.16 -- 2.16 317 537
110 331 531 100 O.sub.2 nil 1-A 1,2 2.16 100 13 197 279 41 O.sub.2
/N.sub.2 1.24.times.10.sup.-4 1-B 1,2,3 2.16 100 13 197 279 41
O.sub.2 /N.sub.2 7.22.times.10.sup.-4 H.sub.2 O.sup.6 1.82 PE-2-1
50.0 B.E.O. 1,3 270 6 6 390 556 83 360 510 75 O.sub.2 nil 1A 1,3,2
6 100 33 166 227 30 O.sub.2 /N.sub.2 1.7.times.10.sup.-5 H.sub.2
O.sup.6 0.78 H.sub.2 O.sup.7 0.67 1B 1,2,3 6 100 33 179 229 25
O.sub.2 /N.sub.2 1.0.times.10.sup.-3 H.sub.2 O.sup.6 3.59 H.sub.2
O.sup.7 2.47 PE-5A-1 50.0 B.E.O. 1 200 7 -- 7 401 577 88 401 577 88
Air 1.9.times.10.sup.-7 2 1,3 7 7 1.3.times.10.sup.-6 3 1,2,3 7 100
35 248 304 28 O.sub.2 7.0.times.10.sup.-3 H.sub.2 O.sup.6 83.4
H.sub.2 O.sup.7 36.0 95.1 4 1,2,3 7 100 105 172 204 16 O.sub.2
5.2.times.10.sup.-4 H.sub.2 O.sup.6 0.6 H.sub.2 O.sup.7 0.2 5 1,2,3
7 83 35 248 304 28 O.sub.2 5.0.times.10.sup.-3 H.sub.2 O.sup.6 50.7
H.sub.2 O.sup.7 20.3.about.100 PE-5B-1 50.0 B.E.O. 1 200 1.4 -- 1.4
755 1079 162 Air 1.4.times.10.sup.-7 2 1,3 1.4 -- 1.4
5.0.times.10.sup.-6 3 1,2 1.4 83 7.0 317 469 76 7.2.times.10.sup.-7
4 1,2,3 1.4 83 7.0 7.6.times.10.sup.-3 H.sub.2 O.sup.6 147. PE-5C-1
50.0 B.E.O. 1 200 1.4 -- 1.4 765 1091 163 Air 7.6.times.10.sup.-8
See-2 1,3 1.4 -- 1.4 4.8.times.10. sup.-8 Note-3 1,2 1.4 83 7.0 328
486 79 5.1.times.10.sup.-7 B -4 1,2,3 1.4 83 7.0
2.7.times.10.sup.-3 PE-7-1 50.0 B.S..sup.9 1,3 200 6.0 83 6.0 331
507 88 331 507 88 O.sub.2 9.2.times.10.sup.-7 H.sub.2 O 0.332 2
1,3,2 83 18 259 357 49 5.3.times.10.sup.-6 1.75 3 1,2,3 83 18 238
334 48 9.0.times.10.sup.-3 148. PE-17 A-1 50.0 DOP.sup.10 1 200 10
-- 10 297 479 91 O.sub.2 nil A-2 1,3 200 10 -- 10 297 479 91 297
479 91 O.sub.2 1.3.times.10.sup .-5 H.sub.2 O.sup.6 1.6 B-1 1,2,3
200 7 83 32 376 552 88 376 552 88 O.sub.2 4.4.times.10.sup.-4
H.sub.2 Notes for Table I: .sup.1 Polyethylene .sup.2 Temperature
of spin block, .degree. C. .sup.3 Butoxyethyl oleate .sup.4 After
initial draw and before leaching; I.D. = Internal Diameter, O.D. =
Outside Diameter. .sup.5 After last stage listed hot-draw (2) or
leach (3) .sup.6 Distilled water .sup.7 2% aqueous albumin .sup.8
No quench bath employed. Air cooled only. .sup.9 Butyl stearate
.sup.10 "Dioctyl" phthalate (Di-(2-ethylhexyl)phthalate)
The relative effects, on fiber permeability, of leaching alone,
post-spin drawing alone and post-spin drawing and then leaching are
apparent from the date in Table I for fibers PE-1, PE-2, PE-5A, -5B
and -5C. The effect of leaching before drawing, rather than
afterwards, is evident from the results for fiber PE-7. It will be
seen that post-spin drawing, and then leaching, is essential to the
attainment of permeabilities above about 1.7.times.10.sup.-5 c.c.
per cm.sup.2 per second per cm. Hg. transmembrane pressure.
It is also apparent, from the results given in Table I, for fibers
PE-17 A-1, 2 and B-1, that a significant improvement in
permeability results when hollow fibers prepared from polyethylene
and dioctyl phthalate, in accordance with the teachings of U.S.
Pat. No. 3,423,491, are post-spin drawn before being leached to
remove the "plasticizer".
EXAMPLE 2
Hollow fibers were spun at 200.degree. c. from a mixture of BEO (47
wt. percent) and Dow high density polyethylene resin 85965 (53 wt.
percent; Melt Index 0.85, Density 0.965, Tensile Strength 4200 psi,
Flexural Modules 24,500 psi). The relative rates of take-up and
extrusion were such that a draw ratio of 14.3/1 resulted. The
nascent fibers were quenched with air only. The dimensions and
mechanical properties (averaged for three replicate specimens each)
of the quenched fibers were as follows: I.D. 380.mu., O.D. 480.mu.,
wall thickness 50.mu.; Tensile Strength 63 gmf (1171 psi), Tensile
Yield Stress 34 gmf (648 psi), Ultimate Elongation 886%, Tensile
Yield Strain 7.5% and Elastic Modules 645 gmf (8600 psi). Some of
these fibers were immersed in hot (83.degree. C.) water for 10
seconds, drawn over a period of about 2 seconds to a wall thickness
of 23 microns (post-spin draw ratio 3.4/1), allowed to soak in the
hot water for about 10 seconds more and then placed on paper to
cool and dry.
The rates of BEO leaching (at 25.degree. C.) from both the drawn
and undrawn fibers with methylene chloride, 1,1,1-trichloroethane
and ethanol were determined and are given in Table II. The observed
dependency of leaching rate on fiber dimensions includes any effect
of drawing per se.
TABLE II ______________________________________ DEPENDENCY OF
LEACHING RATES ON FIBER DIMENSIONS AND LEACHING MEDIUM Percent of
Original BEO Content Left in Fibers Undrawn Drawn
(50.mu.W.T..sup.1) (23.mu.W.T.) Fibers Fibers Leach Time 1/4 hr. 1
hr. 16 hrs. 1/4 hr. 1 hr. 16 hrs.
______________________________________ CH.sub.2 Cl.sub.2 10.0% 6.5%
5.5% 5.5% 5.4% 5.4% CH.sub.3 -CCl.sub.3 24.0 17.0 12.1.sup.2 10.0
8.6 7.3.sup.2 CH.sub.3 -CH.sub.2 OH -- 22.0 -- -- 13.5 --
______________________________________ NOTES: .sup.1 W.T. = Wall
Thickness .sup.2 When the fibers which had been leached with
trichloroethane for 16 hours were further leached with methylene
chloride for 15 minutes, the residual BEO levels were reduced to
.about.5.6% in each instance.
EXAMPLE 3
Replicate lengths of fibers designated in Table I as 5-A-1, 5-B-1
and 5-C-1 (none of which were drawn after spinning), 5-B-3 and
5-C-3 (both post-spin drawn to 5:1 ratio) were leached with ethanol
for 24 hours or with methylene chloride for 4 hours. The residual
BEO contents of the A and B series leached fibers were determined
by gas phase chromatography. Permeabilities of all the leached
fibers were determined as in Example 1, the fiber lengths having
been mounted in beaker U.F. units. The dimensions of the fibers
before leaching are included with the BEO residuals and
permeabilities in Table III-A.
TABLE III-A
__________________________________________________________________________
EFFECTS OF POST-SPIN DRAWING AND LEACH MEDIUM ON RESIDUAL BEO
CONTENT AND PERMEABILITY Post Spin Dimensions Percent of Leach Draw
Before Leach Original BEO # Medium Time Fiber Ratio I.D. O.D. W.T.
Content Left G.P.R.
__________________________________________________________________________
1 ETOH 24 hrs. PE-5A-1 -- 401 577 88 5.1% 6.6.times. 10.sup.-6 2
CH.sub.2 Cl.sub.2 4 " -- " " " 2.4 1.6.times.10.sup.-5 3 EtOH 24
PE-5B-3 5:1 317 469 76 3.7 3.9.times.10.sup.-4 4 CH.sub.2 Cl.sub.2
4 " " " " " 1.6 1.0.times.10.sup.-3 5 CH.sub.2 Cl.sub.2 4 PE-5C-3 "
328 486 79 -- 2.7.times.10.sup.-3 6 EtOH 24 Pe-5B-1 -- 755 1079 162
3.7 8.2.times.10.sup.-6 7 CH.sub.2 Cl.sub.2 4 " -- " " " 3.8
1.4.times.10.sup.-5 8 CH.sub.2 Cl.sub.2 4 PE-5C-1 -- 765 1091 163
-- 4.5.times.10.sup.-6
__________________________________________________________________________
To facilitate comparisons, the date of Table III-A are
recapitulated in Table III-B. For example, leach numbers 6 and 7
(in Table III-A) may be compared (Comparison A in Table III-B) as
differing with respect to both the leach medium employed and
duration of leaching and as being the same with respect to fiber
size and in not having been post-spin drawn.
TABLE III-B
__________________________________________________________________________
Factors Residual Ratio Compar- Held Leach BEO of ison Constant
Varied # Level GPR GPR's
__________________________________________________________________________
A Fiber Leach 7 3.8 1.40.times.10.sup.-5 1.71 size. medium Not and
time. 6 3.7 0.82.times.10.sup.-5 drawn. B Fiber Leach 2 2.4
1.60.times.10.sup.-5 2.43 size. mdium Not and time. 1 5.1
0.66.times.10.sup.-5 drawn. C Fiber Leach 4 1.6 1.0.times.10.sup.-3
2.50 size. medium Not and time. 3 3.7 0.4.times.10.sup.-3 drawn. D
Leach Drawn 3 3.7 39.00.times.10.sup.-5 59.1 medium and time. Fiber
Not drawn 1 5.1 0.66.times.10.sup.-5 size. E Leach Drawn 4 1.6
10.times.10.sup.-4 62.5 medium and time. Fiber Not drawn 2 2.4
0.16.times.10.sup.-4 size. F Leach Fiber 6 3.7 8.2.times.10.sup.-6
1.24 medium size and time. Not drawn. 1 5.1 6.6.times.10.sup.- 6 G
Leach Fiber 7 3.8 1.4.times.10.sup.-5 0.88 medium size and time.
Not drawn. 2 2.4 1.6.times.10.sup.-5 H Leach Drawn to 3 3.7
39.0.times.10.sup.-5 47.6 medium 76.mu. and time. Not drawn 6 3.7
0.82.times.10.sup.-5 162.mu. I Leach Drawn to 4,5 est.
185.times.10.sup.-5 200. medim 77.5.mu. avg. 1.6 average and time.
Not drawn 7,8 est. 0.925.times.10.sup.-5 162.5.mu. avg. 3.8 average
__________________________________________________________________________
Taking comparison A, B, C, F and G as one group and contrasting D,
E, H and I as another group, it is clearly evident that post-spin
drawing before leaching has a much more beneficial effect on
permeability than can be attributed simply to facilitating more
complete solvent (BEO) removal (by fiber wall thickness reduction).
It should be noted that, in fact, the effect of wall thickness
reduction may even by countered to some extent by the concurrent
reduction in fiber inner diameter (making interior wetting by the
leach medium more difficult).
EXAMPLE 4
Hollow fibers are prepared from a molten mixture consisting of
polyethylene resin 70065 (80 wt. %) and 2-butoxyethyl oleate (20
wt.%), in the manner in which fibers PE-5A-6 (Example 1 herein)
were prepared are of comparable dimensions and are found to have
O.sub.2 gas permeabilities, as above defined, of at least
2.times.10.sup.-5.
The foregoing examples are illustrative only and are not to be
construed as restricting the scope of the present invention, which
is limited only according to the appended claims.
Scanning electron micrographs of membranes of this invention reveal
an internal structure of interconnected porous domains. The size of
these porous domains varies from a maximum of .about.1 micron to
the smallest resolveable by the microscope of .about.0.1.mu.. The
inability of some dissolved solutes to pass through the membrane
indicates the minimum pore size is many times smaller than can be
seen with the scanning electron microscope. The domains of porosity
are distributed quite uniformly throughout the membrane. These
photographs reveal that very few, if any, of these porous regions
are completely encapsulated by the polyethylene. Instead, the
porous regions tend to be connected to the bordering porous
regions. This effect of contiguous pores being connected to each
other, leads to the usefulness of the membrane. Being connected,
the adjacent porous regions provide a continuous, if somewhat
tortuous, path from one side of the membrane to the other.
On the basis of the following considerations, maximum pore radii of
the fibers produced by the present method are estimated to range up
to about 50A.
The most rapid and practical method of estimating the effective
pore size of a membrane is by ultrafiltration experiments. A
solution of a solute of know molecular size is pressurized against
one side of the membrane. The permeate which consequently passes
through the pores of the membrane is collected and analyzed. The
rejection coefficient (R) of the membrane is: ##EQU1## where
C.sub.P is the concentration of solute in the permeate, and C.sub.B
is the concentration of solute in the initial solution. In this
process, the pores of the membrane behave as a molecular sieve.
Solute molecules larger than the pore diameter are excluded from
the interior of the pore. The pores then preferentially transport
the very small solvent molecules. Hollow fiber membrane PE-5A-5
(Table I) reject >99.9% of the albumin molecules, allowing only
water to pass through the membrane. The albumin molecule in aqueous
solution exhibits a radius of gyration of approximately 30A. Since
the pores of the microporous polyethylene do not allow the passage
of the solute albumin, the radius of these pores must, at some
point, be smaller than the effective radius of the solute albumin
(30A). Other fibers, such as PE-5A-3, exhibit albumin rejections of
only about 95% and accordingly must include some pores having radii
substantially larger than 30A. Assuming a normal Gausian
distribution of pore sizes, a radius of about 50A appears to be
reasonable maximum for the latter type of fibers.
* * * * *